REVETEMENT POUR AUBES DE TURBINE A CHARGE THERMIQUE ET ABRASIVE

COATING FOR THERMALLY AND ABRASIVELY LOADED TURBINE BLADES

Abrégé français

L'invention concerne un procédé de revêtement d'un substrat entourant une aube de turbine à gaz, comprenant les étapes suivantes : au cours d'une première étape, une matrice de MCrAlY est appliquée au moyen d'un procédé de dépôt physique en phase vapeur ; dans une autre étape, une couche d'oxyde est appliquée au moyen d'un procédé de dépôt physique en phase vapeur.

Abrégé anglais

The invention relates to a method for coating a substrate surrounding a gas turbine blade, comprising the following steps: In a first step, a MCrAIY matrix is applied by means of a PVD method; in a further step, an oxide layer is applied by means of a PVD method.

Revendications

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6
Claims:
1. Method for coating a substrate surrounding a gas turbine blade,
comprising the
steps:
- in a first step, application of a MCrAlY matrix by means of a PVD method
- in a further step, application of a layer by means of a PVD method, wherein
the layer comprises at least one oxide and/or boride and/or carbide and/or
nitride.
2. Method according to Claim 1, characterized in that the PVD method of the
first
and/or of the further step is a cathodic spark evaporation method.
3. Method according to claim 1 or 2, characterized in that the material
source for the
PVD method of the further step is an AlCr target and the coating method is a
reactive method in the course of which oxygen is used.
4. Method according to one of the preceding claims, characterized in that
the
coating is executed as a layer system which comprises two layers or that the
coating is executed as a layer system which comprises a multi-layer
alternating
coating system.
5. Coating system for a gas turbine blade tip comprising, wherein the
coating
comprises at least a first layer with MCrAlY matrix and the coating comprises
at
least a second layer, wherein the second layer comprises at least one oxide
and/or boride and/or carbide and/or nitride.
6. Layer system according to claim 5, characterized in that the coating is
designed
as a multi-layer coating system in which the first and second layer alternate.
7. Gas turbine blade with a coating system according to one of claims 5 or
6.
Date Recue/Date Received 2023-06-14

Description

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Coating for thermally and abrasively loaded turbine blades
Gas turbines have the task of moving a gas in one direction. The gas turbine
comprises
at least one rotor which rotates about an axis and which has a carrier on
whose
periphery a plurality of turbine blades projecting outwards radially are
arranged. In
order to prevent as much as possible the gas from flowing back in the opposite
direction to the desired one, and thus to achieve the highest possible
efficiency of gas
turbines, a turbine liner is provided to ensure a gap with a minimal gap
spacing
between the turbine blade and the turbine liner.
This is achieved by so-called run-in layers on the turbine liner side. These
run-in layers
serve to keep the gap spacing between a turbine blade and the surrounding
turbine
liner as small as possible in order to prevent pressure losses. The run-in
layers are
generally porous and only weakly bonded internally. The consequence of this is
that
is the turbine blade tip, which at the beginning still frequently touches
the run-in layer,
wears it away until essentially contact-free concentricity is achieved with a
minimal gap
spacing.
However, the turbine blades, for example during their thermal expansion or
vibration-
induced deflection of the turbine from the center, can erode the porous and
only weakly
internally bonded run-in layer in an undesired manner and thus increase the
gap
spacing and reduce efficiency.
Blade tip coatings are used to protect the blade tip from wear. These blade
tip coatings
typically consist of abrasive particles (such as cubic boron nitride) embedded
in a
matrix (such as for example MCrAlY). "M" stands for a metal, which is usually
cobalt,
nickel or a cobalt-nickel alloy. "Cr" stands for chromium, "Al" for aluminum
and "Y"
stands for yttrium.
According to the prior art, such coatings are applied by complex and cost-
intensive
processes such as electrolytic or electrophoretic deposition (US5935407A).
A disadvantage of the coatings produced in this way according to the prior art
is the
poor adhesion of the coatings. In the corresponding coating process, the
energy input
Date Recue/Date Received 2023-06-14

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is relatively low and there are hardly any diffusion processes at the
interface to the
substrate surface, which normally ensure acceptable layer adhesion. As a
result,
failure and delamination of the entire coating or of the abrasive particles
can already
occur due to the forces occurring during rotation.
In addition, both the abrasive particles used in the prior art and the matrix
are not
resistant to oxidation at high temperatures and fail due to oxidation. The
abrasive
particles typically used have a particle size in the order of magnitude of the
layer
thickness and can therefore reach from the surface to the interface between
the coating
io and the substrate. If the particle is now oxidized, the blade material
or the
corresponding interface is directly attacked, which can lead to a direct
attack of the
blade material or of the interface between the blade material and the coating
if the
particle is oxidized.
is There is therefore a need to make the coating known from the prior art
more adhesive
and more resistant to oxidation. The object of the present invention is based
on this
need.
The object described above is achieved according to the invention and in
accordance
20 with claim 1 in that depositions from the gas phase by means of PVD
processes are
used for the coating. The use of reactive spark vaporization is particularly
preferred.
The adhesion of blade tip coatings can be significantly improved through the
use of
reactive spark evaporation, since a higher energy input from the gas ions
contributes
25 to improved coating adhesion. Also the manufacturing parameters can be
chosen more
freely, which means that deposition at higher temperatures is possible.
By using different target materials and reactive gases, a bonding layer and/or
matrix
as well as abrasive phases such as oxides, borides, carbides or nitrides can
be
30 deposited in a single process. These phases can either be introduced as
layers in a
multilayer structure or as macroparticles in a matrix. In contrast to
conventional
manufacturing processes for blade tip coatings which are based on electrolytic
or
electrophoretic deposition, very small particles or thin layers can be
completely
embedded in a matrix (e.g. comprising a MCrAlY material and preferably
consisting of
Date Recue/Date Received 2023-06-14

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a MCrAlY material), whereby deeper-lying abrasive phases, even if they are not
resistant to oxidation (which only applies to some), are protected from the
overlying
matrix (e.g. MCrALY). It is thus possible to achieve a protective effect of
the blade tip
against the run-in layer on the liner even in the event of contact or abrasion
situations
after a longer service life than with conventional blade tip coatings.
The coating can consist of several layers, whereby an adhesive layer can be
adapted
to the substrate material in order to enable optimal adhesion.
io The abrasive phase of the blade tip coating can be matched to the run-in
layering on
the turbine liner. These abrasive phases can be built into the coasting either
as layers
or as particles.
Layer thicknesses can be varied in order to adapt the coating to the thermal
and
is abrasive stress profile and thus increase service life.
A thermally less stressable layer can be deposited over the blade tip coating,
for
example to increase the wear resistance of the entire blade tip coating in the
initial run-
in process.
The invention will now be explained in detail using an example and with the
help of the
figures:
FIG. 1 shows schematically a layer system according to the invention made up
of an
MCrAlY layer and an overlying oxide layer.
FIG. 2 shows schematically a multilayer coating system according to the
invention.
FIG. 3 shows the schematic representation of a turbine.
FIG. 4 shows a SEM of the cross-section of a multilayer coating system
according to
the invention after it had been exposed to a temperature of 1200 C for 10
hours.
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FIG. 5 shows the X-ray diffractogram of an abrasive phase of an aluminum oxide-
chromium oxide.
The turbine shown in Figure 3 has at least one turbine blade 5 on a rotating
disc 3 with
a blade base 7 and a blade tip 9. Figure 3 also shows a run-in layer 11 on a
turbine
liner 1 opposite the blade tip 9 and separated from it by a gap G.
On a blade tip made of a superalloy (may for example be single crystal) a
coating of
the composition MCrAlY - aluminum chromium oxide, or a multilayer coating of
alternating layers of MCrAlY - aluminum chromium oxide is deposited.
The MCrAlY is deposited from a MCrAlY material source (= target) by plasma-
enhanced cathodic spark evaporation. The MCrAlY layer can have thicknesses of
0.1
- 100 micrometers according to the required oxidation resistance.
The oxide layer is now deposited on the MCrAlY adhesion and anti-oxidation
layer.
The aluminum chromium oxide layers are deposited from metallic AlCr Targets by
means of reactive cathodic spark evaporation in an oxygen atmosphere. The
oxide
layer can have a thickness of 0.5 to 50 microns.
In order to suppress harmful diffusion processes and thus increase the service
life, the
oxide layer can also be deposited as a multi-layer coating in which the MCrAlY
layer
alternates with an aluminum-chromium oxide layer at regular or other intervals
of 0.1-
20 micrometers.
In this concept, the oxide coating provides a diffusion barrier, which
simultaneously
also serves as an abrasive phase that is not sensitive to oxidation. The
MCrAlY layer
adhering directly to the substrate also provides excellent adhesion to the
blade tip and
the sum of all MCrAlY layers in the entire blade tip coating prevent inwardly
oriented
diffusion processes and efficiently protect the substrate from oxidation.
In very general terms, it can be said that the hardness of the overall layer
system
according to the invention can be adjusted by the ratio of abrasive phase to
MCrAlY in
order to enable optimal removal of the run-in layer. For example, layers with
oxide
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phases in the range of 7 to 25 GPa can be adjusted. However, if harder
abrasive
phases such as nitrides, borides or carbides are used, the hardness can be
increased
up to 45 GPa. For example, the layer in Figure 4 has a hardness of approx. 13
GPa.
5 If aluminum oxide-chromium oxide is used as the abrasive phase, it forms
in the
cathodic spark evaporation a mixed crystal in the corundum structure with a
strong
preferred orientation, as can be seen in Figure 5. In the corundum structure,
the mixed
oxide is in its thermally stable high-temperature modification and can
therefore reach
the high application temperatures without phase transformation. The volume
changes
1.0 associated with the phase transformation, which can lead to the failure
of the layer,
can thus be prevented.
Date Recue/Date Received 2023-06-14

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